Fuel cell system fluid recovery

ABSTRACT

A system and method are provided for fluid collection within a fuel cell system. The fluid collection device includes a fluid collection container which has a gas inlet, a gas outlet, at least one fluid inlet, and a fluid outlet. The at least one fluid inlet allows condensate to enter the fluid collection container. A fluid is contained within the fluid collection container. The gas inlet allows a purge gas to enter the fluid collection container to substantially purge the atmosphere of the fluid collection container through the gas outlet.

TECHNICAL FIELD

This invention relates generally to fuel cells and, more particularly,to recovery of fluid for use by a fuel cell system.

BACKGROUND

Fuel cells electrochemically convert fuels and oxidants to electricity.A Proton Exchange Membrane (hereinafter “PEM”) fuel cell converts thechemical energy of fuels such as hydrogen and oxidants such asair/oxygen directly into electrical energy. The PEM is a solid polymerelectrolyte that permits the passage of protons (i.e., H⁻ ions) from the“anode” side of a fuel cell to the “cathode” side of the fuel cell whilepreventing passage therethrough of reactant fluids (e.g., hydrogen andair/oxygen gases). The direction, from anode to cathode, of flow ofprotons serves as the basis for labeling an “anode” side and a “cathode”side of every layer in the fuel cell, and in the fuel cell assembly orstack.

In general, an individual PEM-type fuel cell may have multiple,generally transversely extending layers assembled in a longitudinaldirection. In a typical fuel cell assembly or stack, all layers whichextend to the periphery of the fuel cells have holes therethrough foralignment and formation of fluid manifolds that generally service fluidsfor the stack. Typically, gaskets seal these holes and cooperate withthe longitudinal extents of the layers for completion of the fluidsupply manifolds. As may be known in the art, some of the fluid supplymanifolds distribute fuel (e.g., hydrogen) and oxidant (e.g.,air/oxygen) to, and remove unused fuel and oxidant as well as productwater from, fluid flow plates which serve as flow field plates of eachfuel cell. Other fluid supply manifolds circulate coolant (e.g., water)for cooling the fuel cell.

In a typical PEM-type fuel cell, the membrane electrode assembly(hereinafter “MEA”) is sandwiched between “anode” and “cathode” gasdiffusion layers (hereinafter “GDLs”) that can be formed from aresilient and conductive material such as carbon fabric or paper. Theanode and cathode GDLs serve as electrochemical conductors betweencatalyzed sites of the PEM and the fuel (e.g., hydrogen) and oxidant(e.g., air/oxygen) which flow in respective “anode” and “cathode” flowchannels of respective flow field plates.

A typical fuel cell system generates condensate water at variouslocations within the system. Therefore, condensate traps have generallybeen designed and located at these locations to aid in the collection ofcondensate. The condensate may be collected and stored in a condensateaccumulation container for future use by the system.

Whereas, it may be undesirable to allow air to escape through thecondensate traps, various arrangements have been designed to prevent airfrom escaping through the traps. For example, a needle and floatarrangement may be utilized to allow condensate to escape when present,however the escape will be plugged when there is no condensate in thetrap.

It has been found that undesirable gasses may accumulate in thecondensate collection container. Such gasses may become entrained ordissolved in the condensate removed in the system. The gasses may buildup in the condensate collection container and present a hazard to thesystem. For example, a flammable gas such as hydrogen may accumulate inthe condensate collection container and present a safety hazard to thesystem.

SUMMARY

The present invention provides a method for recovering fluid from a fuelcell system. The method includes providing the fuel cell system with afluid collection container. The fluid collection container has a gasinlet and a gas outlet. The method further includes collectingcondensate from the fuel cell system then transporting the condensate tothe fluid collection container. A purge gas is provided to the gasinlet, wherein the purge gas flows through the fluid collectioncontainer and exits through the gas outlet.

In another aspect, a method is provided for purging undesirable gas froma fluid container operating with a fuel cell system. The fluid containerhas an inlet and an outlet. The method includes providing a purge gas tothe inlet. The purge gas flows through the fluid container and exitsthrough the outlet.

In another aspect, a fluid collection system is provided for a fuel cellsystem. The fluid collection device includes a fluid collectioncontainer which has a gas inlet, a gas outlet, at least one fluid inlet,and a fluid outlet. The at least one fluid inlet allows condensate toenter the fluid collection container. A fluid is contained within thefluid collection container. An undesirable gas is also contained withinthe fluid collection container. The gas inlet allows a purge gas toenter the fluid collection container to substantially purge theundesirable gas out of the fluid collection container through the gasoutlet.

In another aspect, a method is provided for operating a fuel cellsystem. In general, water is separated from a reactant (process) streamand the water is collected in a collection or accumulation chamber. Theatmosphere of the chamber is purged either continually or periodically.The water may be filtered to maintain a desired purity, and may beheated to generate water vapor (steam). The steam may be used, forexample, to humidify a fuel processor inlet reactant stream to a desiredsteam to carbon ratio (3:1 for example). The steam to carbon ratio maybe adjusted by adjusting the temperature of the humidified stream, byadjusting the amount of steam generated, and by metering the amount ofsteam introduced to the process stream (as examples). In someembodiments, the steam may be generated in a steam generator downstreamfrom the fluid collection container (also referred to as an accumulationchamber). In other embodiments, the steam may be generated within thefluid collection container. In still other embodiments, the steam may begenerated within the fluid collection container, and a fuel processorreactant gas may be used as the purge gas and be humidified by thesteam. Other embodiments and features are possible and within the scopeof the claims presented below.

BRIEF DESCRIPTION OF THE DRAWING

The subject matter that is regarded, as the invention is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other features and advantages ofthe invention will be readily understood from the following detaileddescription of preferred embodiments taken in conjunction with theaccompanying drawings in which:

FIG. 1 is a schematic diagram depicting a fluid recovery system inaccordance with an embodiment of the present invention.

FIG. 2 is a schematic diagram depicting another embodiment of a fluidrecovery system in accordance with the present invention.

DETAILED DESCRIPTION

Referring initially to FIG. 1 there is illustrated, in a schematicdiagram, a fluid recovery system, generally referenced 10, that embodiesthe teachings of the present invention. Fluid recovery system 10comprises a fuel cell stack 12, fuel reformer 14, and fluid collectioncontainer 16. Fuel cell stack 12 typically will include end plates and aworking section therebetween (not shown). The working section mayinclude one or more active sections and can include a selected number ofcooling sections, as will be understood by those skilled in the art.

The working section includes a number of individual fuel cells (notshown) which generally form fluid manifolds for supplying reactant gasor fluids to, removing fluids from, and otherwise communicating and/orservicing fluids as desired within the working section. An anode gassupply line 18 and a cathode gas supply line 20 supply the reactantgases necessary for operation of the fuel cell system. Supply lines 18and 20 may comprise a plurality of individual lines for supplyingreactant gases to fuel cell stack 12. Supply lines 18 and 20 may bepreferably constructed from non-corrosive stainless-steel orpolypropylene, or any other suitable material as may be known in theart.

In the context of this invention a reactant gas may be any substancewhich is classified as a fuel, such as substantially pure hydrogen,methanol reformate or natural gas reformate, or any substance classifiedas an oxidant such as substantially pure oxygen or oxygen containingair, as may be known in the art. Fuel cell stack 12 also preferablyincludes exhaust manifolds 22 and 24 for expelling unreacted fuel andoxidant gases.

A gas supply line 28 carries the incoming gas, such as methanol ormethane, to fuel reformer 14. Fuel reformer 14 produces and introducesas a fuel, such as substantially pure hydrogen, methanol reformate ornatural gas reformate, into anode supply line 18, for use in fuel cellstack 12. During fuel reformation condensate or excess fluid may bepresent in fuel reformer 14, therefore the system may be equipped with acondensate return line 30. Condensate return line 30 transportscondensate and/or fluid from fuel reformer 14 to fluid collectioncontainer 16.

Fluid collection container 16 may be constructed out of any suitablematerial, such as plastic or stainless steel. Those of skill in the artwill appreciate that fluid collection container 16 may include traps 26for collecting fluids condensing or accumulating in the system. Traps 26are connected to various locations of the fuel cell system by fluidlines 27. Traps 26 may have a needle and float arrangement, wherebytransport of gas through traps 26 is blocked when there is no fluid inthe trap. When fluid is in the trap, a float allows the fluid to enterfluid collection container 16. Alternatively, any type of fluid trap maybe used as is known in the art.

Fluid collection container 16 may also have an overflow 32 and a drain34 to aid in controlling the level of the fluid residing within fluidcollection container 16. Drain 34 may be operated by a valve 36 incommunication with a level sensor (not shown) mounted within fluidcollection container 16. It will be appreciated by those of skill in theart that fluid and/or condensate may be transported to fluid collectioncontainer 16 from any area of the fuel cell system which fluid and/orcondensate may be present. Also, multiple fluid collection containersmay be used in conjunction with one another to afford greater designflexibility to the system.

From time to time undesirable gas may become entrained or dissolved inthe fluid being transported and ultimately reside in fluid collectioncontainer 16. Build up of any undesirable gas, such as hydrogen, maypresent a hazard to operation of the system. Undesirable gas may beliberated during operation of the fuel cell by introducing a purge gas,such as air, into fluid collection container 16. The purge gas entersfluid collection container 16 through inlet 38, and exits along with anyundesirable gas through outlet 40. Inlet 38 and outlet 40 may comprise avalve capable of opening and closing depending on the operatingconditions of the fuel cell system.

As is shown in FIG. 1, the cathode exhaust stream may be utilized topurge fluid collection container 16 from the accumulation of anyundesirable gases. In some embodiments, this purge gas stream may thenbe sent to an oxidizer (not shown) such as a burner to remove anycombustible gasses before the exhaust is vented to the atmosphere (as anexample). Alternatively, outside air or a suitable purge gas fromanother source may be used to liberate any undesirable gas from fluidcollection container 16.

The fluid collected in fluid collection container 16 may then berecirculated through the fuel cell system for use at various locationsrequiring such fluid. The fluid may exit fluid collection container 16through an outlet 42 and into a fluid line 44 for recirculation. If thefluid collection container is collecting, for example, deionized water,purging the container may impart ions to the deionized water therebyrendering it conductive. Therefore, the fluid recovery system may have apolishing filter 46 connected to the recirculating fluid line. Polishingfilter 46 may comprise a ResinTech filter model number mrn-1, forexample, however any suitable polishing/scrubbing filter may be used asis known in the art.

At various times of operation, such as start up, fluid will be requiredto be added to fluid recovery system 10. When additional fluid isrequired to be added to the system, fluid may be added from a source 48(i.e. home water supply line) and deionized by use of a polishing filter50. Polishing filter 50 may be of similar construction to polishingfilter 46 described herein. The fluid may then pass through fluid line52 and into fluid collection container 16 for use by the system. Inother embodiments, the fluid may not need to be filtered, or the degreeof purity required may vary.

An alternate embodiment of a fluid recovery system is illustrated isFIG. 2, in schematic format. Fluid recovery system 100 comprises a fluidcollection container 116, a fuel reformer 114, an incoming reactant gasstream 110, and a steam generator 118. In addition to the componentsdepicted in FIG. 2, the present alternate embodiment may be utilizedwith a fuel cell system and contain components similar to thosedescribed with reference to FIG. 1.

As shown in FIG. 2, condensate is transported through fluid line 127 andis separated from the reactant gas streams by fluid trap 126. The fluidthen enters fluid collection container 116. A reactant gas enters fluidcollection container 116 through an inlet 120. A steam generator 118heats the fluid contained within fluid collection container 116 tocreate steam. Steam generator may comprise a heat exchanger, which usesheated coolant from a fuel cell system to generate the steam.Alternatively, any type of steam generator may be utilized as is knownin the art.

The humidified reactant gas then exits fluid collection container 116through outlet 122, and is transported via fluid line 124 to fuelreformer 114. As will be appreciated by those of skill in the art, theparticular fuel processing system that is used may dictate an optimalsteam to carbon ratio, more than 2:1 for example, for a typicalautothermal reforming system. The steam to carbon ratio refers to theratio of water molecules to carbon atoms in the gas phase. In oneembodiment, this ratio may be achieved by adjusting the temperature ofthe mixed fuel and steam (above 70° C. for example). In otherembodiments, the ratio may also be achieved by adjusting the rate ofsteam generated or by metering a desired amount of steam into thestream.

Although preferred embodiments have been depicted and described indetail herein, it will be apparent to those skilled in the relevant artthat various modifications, additions, substitutions and the like can bemade without departing from the spirit of the invention and these aretherefore considered to be within the scope of the invention as definedin the following claims.

What is claimed is:
 1. A method of operating a fuel cell systemcomprising: separating water from a reactant stream; collecting thewater in an accumulation chamber; purging an atmosphere of theaccumulation chamber with a purge gas; and heating the water to generatesteam.
 2. The method of claim 1, further comprising: filtering the waterbefore the water is heated to generate steam.
 3. The method of claim 1,further comprising: mixing the steam with a gaseous fuel processorreactant stream.
 4. The method of claim 3, further comprising: adjustingthe temperature of the mixed fuel processor reactant stream to obtain adesired steam to carbon ratio.
 5. The method of claim 4, wherein thesteam to carbon ratio is at least 2:1.
 6. The method of claim 4, whereinthe steam to carbon ratio is at least 4:1.
 7. The method of claim 4,wherein the steam to carbon ratio is less than 5:1.
 8. The method ofclaim 3, further comprising: adjusting a rate at which the water isheated to obtain a desired steam to carbon ratio.
 9. The method of claim8, wherein the steam to carbon ratio is at least 3:1.
 10. The method ofclaim 3, wherein only a portion of the steam is mixed with the fuelprocessor reactant stream.
 11. The method of claim 2, wherein the filteris a deionization bed.
 12. The method of claim 1, wherein the purgingstep is conducted continuously.
 13. The method of claim 1, wherein thepurging step is conducted at periodic intervals.
 14. The method of claim1, wherein the purge gas is air.
 15. The method of claim 14, furthercomprising: supplying the air from a fuel cell cathode inlet stream. 16.The method of claim 14, further comprising: supplying the air from afuel cell cathode outlet stream.
 17. The method of claim 1, wherein theaccumulation chamber receives water from multiple sources in the fuelcell system.
 18. The method of claim 1, further comprising: flowing thepurge gas through the water accumulation chamber and into an oxidizer.19. The method of claim 1, wherein the heating step is conducted withinthe accumulation chamber.
 20. The method of claim 1, wherein the purgegas is a fuel processor reactant stream.